Composite Metal Forming Tool Surface for Lower Hold-Down Force
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Solution Overview
Problem
Conventional metalworking tools made entirely of metal require high hold-down forces and can cause distortion or surface defects during metal forming processes, and they are cumbersome to produce and rework.
Innovation Solution
A metalworking tool is produced using a first partial mold made of plastic with varying material properties applied to its surface, and a second partial mold, which can be metal or plastic, to reduce the hold-down force and enhance dimensional accuracy, allowing for reduced manual effort and increased processing speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metalworking tools are made entirely of metal, then they provide sufficient structural strength, but they require high hold-down forces and cause distortion or surface defects during metal forming
Solution Approach 1:
The patent applies composite materials by combining plastic base body with metal inlays or coatings. The plastic provides low friction and reduced hold-down forces, while metal inlays (such as hardened steel inserts) provide localized strength and wear resistance. This composite structure eliminates distortion and surface defects caused by pure metal tools while maintaining necessary structural integrity.
Solution Approach 2:
The patent implements local quality by applying different materials to different areas of the tool surface. Metal inlays or coatings are applied only to specific contact areas where high strength and wear resistance are needed, while the remaining plastic surfaces maintain low friction properties. This localized application of material properties resolves the contradiction between overall tool strength and localized surface quality.
2Reliability
If metalworking tools are made entirely of metal, then they ensure durability, but they are cumbersome to produce and rework
Solution Approach 1:
The patent segments the tool into a plastic base body and separate metal inlays or coatings. The plastic base can be manufactured using efficient molding processes, while metal components can be produced separately and then integrated. This segmentation allows each material to be optimized and manufactured independently, reducing overall production complexity while maintaining durability through the metal components.
3Manufacturing precision
If plastic is used for the base body with different material properties in different areas, then hold-down force is reduced and dimensional accuracy is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies parameter changes by varying the material properties (friction coefficient, elasticity, hardness) of the plastic in different areas of the base body. Different plastic materials or surface treatments are applied to different zones to optimize contact characteristics, reduce hold-down forces, and improve dimensional accuracy. This controlled variation of material parameters achieves precision while managing manufacturing complexity through systematic material selection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tool reduces the hold-down force required for metal forming, minimizes distortion and surface defects, and allows for faster production and reworking, with improved dimensional accuracy and reduced mass-related dynamic effects.
Implementation Method 1
Plastic is filled into the at least one cavity and cured, the plastic being connected to the surface of the base body
Data Source
Figure 1a~1b
Figure 1c
Figure 1d
AI summary
The invention relates to a method for producing a first mould element (4) for a metal machining tool (6), wherein the first mould element (4) is configured as a holding-down means, wherein, in order to produce the first mould element (4), a main body (2) made of plastics material is provided, wherein a surface (8) of the main body (2) is subdivided into a plurality of regions (10, 12), wherein at least one casting (18) is arranged on at least one region (10, 12) of the surface (8) of the main body (2), wherein the at least one casting (18) and the at least one region (10, 12) of the surface enclose at least one cavity (24, 26) which forms a negative mould for a layer (14, 16) of plastics material to be applied to the at least one region (10, 12), wherein plastics material is filled into the at least one cavity (24, 26) and cured, wherein the plastics material is connected to the surface (8) of the main body (2) in the at least one region (10, 12) and is applied thereto, forming the layer (14, 16). A metal machining tool produced by this method is likewise disclosed.